Back to EveryPatent.com
United States Patent |
5,678,715
|
Sjostedt
,   et al.
|
October 21, 1997
|
Composite stacking frame assembly for shipping container
Abstract
An intermodal shipping container including a top wall, a bottom wall,
opposite side walls, and a composite frame structure including upper and
lower longitudinals interconnecting the side walls with the top and bottom
walls, and a pair of stacking frame assemblies for supporting the weight
of one or more other containers. Each stacking frame assembly includes a
pair of vertical stacking posts each integrated into one of the side walls
and a horizontal crossmember integrated into the top wall. The stacking
posts and the crossmember are pultruded of composite material, and the
stacking post can include layers of different material to optimize
performance. Each of the stacking frame assemblies also includes a pair of
upper connector assemblies at the intersections between the upper
longitudinal members, the stacking posts, and the crossmember, and a pair
of lower connector assemblies at the intersections of the lower
longitudinal members and the stacking posts. Each connector assembly
includes a hollow metal fitting, a pair of splice plates adhesively bonded
to one of the stacking posts to form a double lap joint, and a tubular
member telescopically received in, and adhesively bonded to, one of the
longitudinal members to form a telescopic lap joint.
Inventors:
|
Sjostedt; Robbie J. (Oregon, WI);
Schaffer; Brent G. (Janesville, WI);
Tedesco; James (Janesville, WI)
|
Assignee:
|
Stoughton Composites, Inc. (Brodhead, WI)
|
Appl. No.:
|
400650 |
Filed:
|
March 7, 1995 |
Current U.S. Class: |
220/1.5; 220/615; 220/622 |
Intern'l Class: |
B65D 087/00 |
Field of Search: |
220/4.26,1.5,4.28,615,616,621,622
217/13
|
References Cited
U.S. Patent Documents
2962323 | Nov., 1960 | McBride | 296/28.
|
3003810 | Oct., 1961 | Kloote et al. | 296/31.
|
3128897 | Apr., 1964 | Wilkins | 220/1.
|
3401814 | Sep., 1968 | Chiswell et al. | 220/1.
|
3450830 | Jun., 1969 | Golder | 220/1.
|
3456829 | Jul., 1969 | Glassmeyer | 220/1.
|
3561633 | Feb., 1971 | Morrison et al. | 220/1.
|
3801177 | Apr., 1974 | Fylling et al. | 312/351.
|
3854620 | Dec., 1974 | Saidla | 220/1.
|
3907148 | Sep., 1975 | Meller et al. | 220/1.
|
4144984 | Mar., 1979 | Saunders | 220/1.
|
4258520 | Mar., 1981 | Rehbein | 52/522.
|
4325488 | Apr., 1982 | Ketner | 220/1.
|
4366905 | Jan., 1983 | Forshee | 220/1.
|
4576300 | Mar., 1986 | Kedzior | 220/1.
|
4589565 | May., 1986 | Spivey | 220/1.
|
4729570 | Mar., 1988 | Welch, Jr. | 200/5.
|
4730428 | Mar., 1988 | Head et al. | 52/300.
|
4810027 | Mar., 1989 | Ehrlich | 296/181.
|
4940279 | Jul., 1990 | Abott et al. | 296/181.
|
5178292 | Jan., 1993 | Korzeniowski | 220/1.
|
5279436 | Jan., 1994 | Elliott et al. | 220/1.
|
5507405 | Apr., 1996 | Thomas et al. | 220/1.
|
Primary Examiner: Moy; Joseph M.
Attorney, Agent or Firm: Michael Best & Friedrich
Parent Case Text
This application is the continuation application of Ser. No. 08/066,393
filed May 21, 1993 now abandoned.
Claims
We claim:
1. An intermodal shipping container comprising
a frame including a plurality of horizontally extending longitudinal
members, and a stacking frame assembly, said stacking frame assembly
including a vertical stacking post made of a non-metallic composite
material, and a connector assembly, said connector assembly including a
hollow fitting positioned on top of said stacking post, first lap joint
means for attaching said fitting to said stacking post, said first lap
joint means including a pair of first plates extending downwardly from
said fitting, said first plates sandwiching said stacking post, and each
of said first plates being adhesively bonded to said stacking post to fix
said first plates to said stacking post, and second lap joint means for
attaching said fitting to said one longitudinal member, said second lap
joint means including an adhesive material, and
top, bottom, and opposite side walls mounted on said frame to form a
box-like structure, one of said side walls including said stacking post.
2. An intermodal shipping container as set forth in claim 1 wherein said
stacking post is hollow, and wherein said first lap joint means includes
means for clamping said first plates to said stacking post, and means for
reinforcing said stacking post against clamping forces, said means for
reinforcing including a block positioned within said stacking post and
directly between said first plates.
3. An intermodal shipping container as set forth in claim 1, wherein said
one side wall has opposite interior and exterior surfaces contained in
spaced apart parallel planes, wherein said stacking post includes
oppositely facing surfaces each recessed from one of said interior and
exterior surfaces, and wherein each of said first plates is adhesively
bonded to one of said oppositely facing surfaces of said stacking post so
that said first plates are substantially confined between said parallel
planes.
4. An intermodal shipping container as set forth in claim 1 wherein said
stacking frame assembly includes a horizontal crossmember forming part of
said top wall, said crossmember being made of a non-metallic composite
material, and wherein said connector assembly includes third lap joint
means for attaching said fitting to said crossmember, said third lap joint
means including a metallic member extending from said fitting, overlapping
said crossmember, and being adhesively bonded to said crossmember.
5. An intermodal shipping container as set forth in claim 4 wherein said
metallic member is a tubular member telescopically received within said
crossmember, said tubular member being adhesively bonded on opposite sides
to said crossmember.
6. An intermodal shipping container as set forth in claim 1 wherein said
second lap joint means includes a pair of second plates, said second
plates sandwiching said one longitudinal member.
7. An intermodal shipping container as set forth in claim 6 wherein said
second lap joint means includes a reinforcing member telescopically
received in said longitudinal member and adhesively bonded thereto.
8. An intermodal shipping container as set forth in claim 5 wherein said
third lap joint means includes a pair of plates sandwiching said
crossmember, and means for clamping said pair of plates sandwhiching said
crossmember to said crossmember.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to shipping containers, and more
particularly to shipping containers configured to be used in vertically
stacked relation with one another such that each container is capable of
supporting one or more additional containers thereon.
2. Reference to Prior Art
The use of containerized lading equipment is common in the shipping
industry due to the reduced handling and expedited loading and unloading
advantages that shipping containers provide. For example, intermodal
shipping containers can be transported from point to point using a variety
of carriers such as ships, trucks and rail cars and several modes of
transportation are commonly used to transfer individual shipping
containers to their final destinations.
Shipping containers are provided with fittings or castings including
openings used in conjunction with container securement devices to secure
the containers on various vehicles or to each other, or in conjunction
with lifting cranes for manipulating the containers. The fittings are
typically positioned in standard locations along the top and bottom of the
container. For example, ISO (International Standards Organization)
containers which are 40 feet long and approximately 96 inches wide include
fittings at each of their eight corners. Similarly, domestic containers of
48 feet lengths typically include fittings positioned inwardly of their
ends to match the fittings in 40 foot ISO containers.
Regardless of where located, the fittings are supported at the four corners
of a rigid frame structure. The frame structure includes metal horizontal
cross members and vertical stacking posts. To fully utilize ground or
floor space when in storage or when being transported, containers are
often vertically stacked as many as six or more high, and the vertical
stacking posts in the containers must be capable of supporting such loads.
To meet industry standards, the stacking posts are made of metal and are
considerably thicker than the side walls of the container such that the
stacking posts extend into the interior of the container and reduce
payload space. Metal frame components are also heavy and, in insulated or
refrigerated shipping container applications, thermal losses through the
metal frame components can significantly adversely affect the thermal
performance of the container.
SUMMARY OF THE INVENTION
The invention provides an intermodal shipping container including an
improved stacking frame assembly that is constructed of components
including vertical stacking posts and horizontal crossmembers made of
reinforced plastic composite material. The components are configured to be
contained within the confines of the container walls to maximize the
interior dimensions of the container. The composite components have
superior insulating qualities to metal frame components and are light
weight to decrease the overall weight of the container. In addition, the
composite components possess the necessary structural properties to meet
industry load bearing standards.
More particularly, the invention provides a stacking frame assembly
including stacking posts made of composite material. The stacking posts
preferably have a cross-sectional thickness that approximately matches
that of the side walls of the container so that the posts are capable of
being fully integrated into the walls to provide maximum interior
dimensions without increasing the exterior width of the container.
In one embodiment, the stacking posts are formed via pultrusion and include
a resin binder material and a filamentary material that is preferably
predominantly oriented in a direction parallel to the axis of pultrusion
of each stacking post. This filament orientation provides the stacking
posts with quasi-orthotropic properties that improve column stability. The
quasi-orthotropic nature of the posts also improves insulating ability. In
particular, thermal flux across the stacking post is a function of its
overall thermal conductivity. With the filamentary material oriented
predominantly in a direction transverse to the direction of thermal flux
(i.e., perpendicular to the thickness dimension of the stacking post),
thermal flux is largely controlled by the thermal conductivity of the
resin binder material which is lower than that of the filamentary
material.
The invention also provides an intermodal shipping container having means
including vertical stacking posts for supporting the weight of one or more
other shipping containers thereon. Each of the stacking posts is
preferably incorporated as a modular part of one of the side walls of the
container and includes means for interfitting with modular panel members
on its opposite sides. The stacking posts are made of non-metallic
composite material and each has a thickness that is no greater than that
of the side wall in which it is incorporated so that the stacking posts
are confined substantially entirely between the interior and exterior
surfaces of the side walls.
The invention also provides hybrid stacking posts which can be designed to
suit a specific container application. For example, by using different
filamentary materials in the same stacking post strength, insulating
ability and thickness of the post can be manipulated for optimal
performance. Different filamentary materials can be easily incorporated
into the stacking posts during the pultrusion operation. In particular,
hybrid stacking posts can be made of composite material including a resin
binder, a first filamentary material, and a second filamentary material
different from the first filamentary material. In one embodiment the
stacking posts have separate layers including different filamentary
materials that have different moduli of elasticity and thermal
conductivities.
The invention also provides a shipping container having metal connector
assemblies used to interconnect the container with other containers or
with a support surface, such as a ship deck or rail car bed. The connector
assemblies are positioned at the intersections of the stacking posts and
the upper and lower longitudinal rails of the container. When manipulating
a container with a lifting crane or when interconnected containers are
subjected to loads tending to shift those containers relative to one
another, bending loads are encountered by the frame components of the
container. Those bending loads tend to twist the frame components relative
to one another. This presents a special problem for composite frame
components since twisting results in the undesireable application of shear
loads to the frame components.
Applicant has devised a unique scheme for mounting the connector assemblies
on the composite frame components so as to elliminate or at least minimize
the effects of twisting between the various composite frame components. In
one embodiment, the connector assemblies each include a hollow locking
member receiving fitting that is provided with metallic members or plates
which overlap the frame components and which are adhesively bonded thereto
to rigidly fix the fitting to the frame components. Optional clamping
means can also be provided to clamp the connector assembly to the frame
components to reinforce the adhesive joint.
The invention further provides an intermodal shipping container including a
frame having a pair of composite upper longitudinal members
interconnecting the side walls of the container with the top wall, and a
pair of composite lower longitudinal members interconnecting the side
walls with the bottom wall. The frame also includes a pair of stacking
frame assemblies which may be positioned at the ends of the container or
at intermediate locations spaced inwardly of the ends of the container, as
desired. Each stacking frame assembly includes a pair of vertical
composite stacking posts integrated into the side walls and a composite
crossmember integrated into the top wall. The stacking frame assemblies
also include upper connector assemblies at the intersections of the
stacking posts, the crossmembers and the upper longitudinal members, and
lower connector assemblies at the intersections of the stacking posts and
the lower longitudinal members. Each connector assembly includes a lock
receiving fitting and a pair of splice plates that fit over the stacking
posts and that are adhesively bonded thereto to form a double lap joint.
Each connector assembly also includes at least one member that is
telescopically received in one of the longitudinal members and that is
adhesively bonded thereto to form a telescopic lap joint. Optional
clamping means, such as fasteners, can also be used to provide additional
strength and rigidity at the lap joints.
Other features and advantages of the invention will become apparent to
those skilled in the art upon review of the following detailed
description, claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an intermodal shipping container embodying
various features of the invention.
FIG. 2 is a reduced side elevational view of the container illustrated in
FIG. 1.
FIG. 3 is a top plan view of the container illustrated in FIG. 2.
FIG. 4 is a bottom plan view of the container illustrated in FIG. 2.
FIG. 5 is a front elevational view (taken from the left in FIG. 2) of the
container.
FIG. 6 s a rear elevational view (taken from the right in FIG. 2) of the
container.
FIG. 7 s an enlarged view taken along line 7--7 in FIG. 3.
FIG. 8 is an enlarged view taken along line 8--8 in FIG. 2 and showing
interconnected wall panels forming a portion of a side wall of the
container.
FIG. 9 is a further enlarged view of a portion of the side wall illustrated
in FIG. 8 and showing a joint between adjoining wall panels.
FIG. 10 is a still further enlarged view of a portion of one of the wall
panels illustrated in FIG. 9.
FIG. 11 is a perspective view showing assembly of a pair of wall panels to
form a joint such as is illustrated in FIG. 9.
FIG. 12 is an enlarged view taken along line 12--12 in FIG. 2 and showing a
portion of a side wall of the container including a stacking post.
FIG. 13 is an enlarged view taken along line 13--13 in FIG. 4 and showing
interconnected wall panels forming a portion of the bottom wall of the
container.
FIG. 14 is a side elevational view of one of the wall panels shown in FIG.
4.
FIG. 15 is an enlarged view taken along line 15--15 of in FIG. 3 and
showing interconnected wall panels forming a portion of the top wall of
the container.
FIG. 16 is an enlarged view taken along line 16--16 in FIG. 3 and showing a
portion of the top wall of the container including a horizontal beam.
FIG. 17 is an enlarged view of a portion of the container illustrated in
FIG. 3 and showing a top intermediate connector installation.
FIG. 18 is a view taken along line 18--18 in FIG. 17.
FIG. 19 is a cross-sectional view of the top intermediate connector
installation.
FIG. 20 is a perspective view of the top intermediate connector assembly
forming part of the installation illustrated in FIG. 17.
FIG. 21 is a top plan view, partially cut away and in section, of the top
intermediate connector assembly.
FIG. 22 is a side elevational view, partially cut away and in section, of
the top intermediate connector assembly.
FIG. 23 is a view taken along line 23--23 in FIG. 20.
FIG. 24 is an enlarged view of a portion of the top intermediate connector
assembly illustrated in FIG. 21 and showing that portion prior welding
that assembly together.
FIG. 25 is an enlarged view of a portion of the container illustrated in
FIG. 4 and showing a bottom intermediate connector installation.
FIG. 26 is a side elevational view of the bottom intermediate connector
installation illustrated in FIG. 25.
FIG. 27 is a perspective view of the bottom intermediate connector assembly
forming part of the installation illustrated in FIG. 25.
FIG. 28 is a view taken along line 28--28 in FIG. 5 and shows an enlarged
cross-sectional view of the front of the container.
FIG. 29 is a view taken along line 29--29 in FIG. 5 and shows another
enlarged cross-sectional view of the front of the container.
FIG. 30 is an enlarged view of a portion of the container illustrated in
FIG. 2 and showing a front corner connector installation.
FIG. 31 is a bottom plan view of the front corner connector installation
illustrated in FIG. 30.
FIG. 32 is a top plan view of the front corner connector assembly forming
part of the installation illustrated in FIG. 30.
FIG. 33 is an enlarged view of the rear door frame of the container taken
along line 33--33 in FIG. 6.
FIG. 34 is an enlarged view of the rear door frame taken along line 34--34
in FIG. 6.
FIG. 35 is an enlarged view of the rear door frame and doors taken along
line 35--35 in FIG. 6.
FIG. 36 is an enlarged view similar to FIG. 9, but showing a splice joint
configuration wherein a replacement panel has been installed.
FIG. 37 is a view similar to FIG. 36 and showing an alternative splice
joint configuration.
FIGS. 38-41 are cross-sectional views similar to FIG. 12 and showing
alternative stacking post configurations. FIG. 42 is a side elevational
view of an alternative container construction.
FIG. 43 is a top plan view of the container illustrated in FIG. 42.
FIG. 44 is a bottom plan view of the container illustrated in FIG. 42.
FIG. 45 is a front view (taken from the left in FIG. 42) of the container.
FIG. 46 is an enlarged view of a portion of the container taken along line
46--46 in FIG. 45.
Before one embodiment of the invention is explained in detail, it is to be
understood that the invention is not limited in its application to the
details of construction and the arrangement of components set forth in the
following description or illustrated in the drawings. The invention is
capable of other embodiments and of being practiced or being carried out
in various ways. Also, it is to be understood that the phraseology and
terminology used herein is for the purpose of description and should not
be regarded as limiting.
GENERAL DESCRIPTION
Illustrated the drawings is a vehicle or container body embodying the
invention. The container body can be integrated into a variety of freight
hauling vehicles, such as to serve as a trailer or truck body, a railroad
car body, a freight shipping container, or the like. In the illustrated
embodiment, the container body is a shipping container 10. More
particularly, the shipping container 10 illustrated in FIGS. 1-6 is an
insulated intermodal domestic container having a length of about 48 feet
and a width of about 96 inches. However, as will be apparent to those
skilled in the art, the invention is applicable to container bodies of
various sizes and to insulated or uninsulated container bodies.
As shown in FIGS. 1-6, the container comprises a frame 14 on which walls
are mounted, as is further explained below, to form a box-like structure
defining (FIG. 1) a cargo receiving interior space 18. The frame 14
includes (FIG. 4) a pair of lower longitudinal members or rails 22.
Referring to FIG. 7, each lower rail 22 (only one is shown in FIG. 7)
includes a longitudinally extending axis 26 and a tubular portion 30
having a recessed lower surface 34. In the illustrated embodiment, the
tubular portion 30 is filled with an insulating material I, such as
expanded foam insulation for example. Each lower rail 22 also includes an
upwardly extending outer flange 38 and an inwardly extending lower flange
42 that is downwardly offset relative to the lower surface 34.
As shown in FIGS. 1, 2 and 4, each lower rail 22 is provided with front and
rear rail sections 46 and 50 at its opposite ends. The rail sections 46
and 50 are preferably shaped identically to the lower rail 22 minus the
two outwardly exposed sides (as seen in FIG. 7) of the tubular portion 30.
The rail sections 46 and 50 are made of metal and are provided with a
stiffening gussets 54.
The frame 14 also includes (FIG. 3) a pair of upper longitudinal members or
rails 58 parallel to the lower rails 22. To accommodate lock receiving
fittings, as is more fully explained hereinafter, the upper rails 58 are
each cut into sections including (FIGS. 1-3) front, rear, and central
sections 62, 66, and 70, respectively. Referring again to FIG. 7, each
upper rail 58 (only one is shown in FIG. 7) includes a longitudinally
extending axis 74 and a tubular portion 78. The tubular portion 78 is
filled with insulation I and has a recessed upper surface 82. Each upper
rail 58 also includes a downwardly extending outer flange 86 and an
inwardly extending lower flange 90 that is slightly downwardly offset
relative to the bottom side of the tubular portion 78.
The frame 14 also includes lateral members, several of which are assembled
(FIGS. 1-5) into a front frame assembly 94. The front frame assembly 94
includes opposite vertically extending front corner posts 98. As shown in
FIG. 28, each corner post 98 is hollow and has a longitudinally extending
axis 102. Each corner post 98 also includes an inwardly extending flange
106 and a set of vertical flanges 110 that project rearwardly (i.e.,
upwardly in FIG. 28). The flanges 110 have opposed inwardly facing tapered
surfaces that form a female member capable of interfacing with a side wall
of the container 10, as is further explained below, and the upper end
portions of the flanges 110 are removed to accommodate the tubular
portions 78 of the upper rails 58. The corner posts 98 are also filled
with insulation I, and post caps 114 (FIG. 1) are adhesively sealed over
the top of each post.
The front frame assembly 94 also includes (FIGS. 1 and 5) upper, lower and
intermediate beams 118, 122 and 126, respectively. Those beams extend
between the corner posts 98 and are preferably adhesively bonded and
sealed thereto. In the illustrated embodiment, the intermediate beam 126
is spaced sufficiently below the upper beam 118 to provide an opening 130
(FIG. 5) for a refrigeration unit (not shown).
As shown in FIG. 29, the upper, lower and intermediate beams 118, 122 and
126 have respective longitudinally extending axes 134, 138, and 142, and
are hollow to also receive insulation I. The upper and lower beams 118 and
122 are provided with sets of rearwardly extending flanges 146 and 150,
respectively. The flanges 146 and 150, like the flanges 110 on the corner
posts 98, form female members which are adapted to interface with top and
bottom walls of the container 10, respectively. The lower and intermediate
beams 122 and 126 also include a male member 154 and a set of downwardly
extending flanges 158, respectively, that are adapted to interface with a
front wall as explained below.
While the frame members thus far discussed can be made of any suitable
material such as metal for example, in the illustrated arrangement each of
those members, except for the rail sections 46 and 50, is made of
composite material such as fiber reinforced plastic. It is also preferred
that those components be integrally made as unitary pultrusions.
Pultrusion apparatus and methods known in the art are disclosed in U.S.
Pat. No. 3,769,127 issued Oct. 30, 1973 to Goldsworthy et. al., and in
U.S. Pat. No. 3,556,888 issued Jan. 19, 1971, and U.S. Pat. No. 2,871,911
issued Feb. 3, 1959, both to Goldsworthy, all of which are incorporated
herein by reference. Briefly, the pultrusion process involves passing
fibrous material through a resin bath and pulling the resulting composite
through a die wherein the material is formed into the desired shape and
cured. Thereafter, the resulting continuous pultrusion is cut into desired
lengths.
The composite material used to produce the aforementioned composite frame
components preferably includes a resin binder material, such as polyester
resin which is sold by Owens-Corning as Model No. E606-6-12. Other
suitable resins include, for example, various polyesters, polypropylenes,
phenolics, epoxies, and polycarbonites. The resin material can, if
desired, be colored to eliminate the need for painting. The composite
material also preferably includes a multi-directional array of filamentary
material dispersed throughout the cross-section of the pultrusion. A
suitable filamentary material is known in the industry as 113E-glass
roving. Possible filamentary material substitutes include, for example,
glass fibers known in the industry as E-, S-, S2- and A-glass fibers, as
well as carbon, graphite, boron, and quartz fibers.
The composite material is as much as several hundred times less thermally
conductive than metal, and possesses the necessary structural properties
to withstand the loads encountered when used in a shipping container or
other vehicle body. In both regards, Applicant has recognized the
advantages that can be achieved by forming composite container components
using the pultrusion process. In particular, the pultrusion process is
well suited for producing products having multi-directional fiber arrays
with a predominance of fibers being oriented in a direction parallel to
the axis of pultrusion (i.e., the longitudinally extending axes of the
products). Pultrusions with that fiber orientation possess desireable
thermal and structural properties. In particular, that fiber orientation
stiffens the pultrusion to improve load carrying ability in the
longitudinal or lengthwise direction. Also, thermal flux across the
pultrusion in a direction transverse to the pultrusion axis is restricted
since it is primarily controlled by the thermal conductivity of the resin
which is much lower than that of the fibers.
In the particular embodiment illustrated in FIGS. 1-6, the intermodal
container 10 is useable as a trailer body and the frame 14 is provided
with means for accommodating a trailer chassis (not shown). As shown in
FIG. 4, the chassis accommodating means includes a pair of spaced apart
steel rails 162 extending rearwardly from the front of the container 10
and a steel crossmember 166 welded across the rear ends of the steel rails
162 to provide a channel 170. A chassis is receivable in the channel 170
in a known manner that is not further discussed.
The frame 14 also includes (FIG. 6) a rear door frame 174. In the
particular embodiment illustrated in the drawings, the door frame 174 is a
welded steel structure including a lower crossmember 178 providing (FIG.
33) a lower door sill 182. The door frame 174 also includes an upper
crossmember 186 providing (FIG. 35) an upper door sill 188, and opposite
rear corner posts 190 (one is shown in FIG. 34) interconnecting the upper
and lower crossmembers 176 and 178 and providing side door sills 194.
To facilitate loading and unloading of the container 10 a set of insulated
doors 198 (FIG. 6) are mounted on the rear door frame 174. While in the
illustrated arrangement the doors 198 are standard, in other arrangements
the doors 198 can be constructed, for example, by pultruding hollow
composite door panels or shells (not shown) and filling those panels with
expanded foam insulation. The thermal advantages of such a construction
are mentioned above and are further explained below in connection with the
discussion of the walls of the container 10.
To facilitate attachment of the container 10 to a supporting surface, such
as the aforementioned trailer chassis for example, the frame 14 is also
provided with corner fittings 202 at the lower front and rear corners of
the container 10. The corner fittings 202 are preferably standard fittings
meeting the specifications of the Association of American Railroads, and
are configured to receive standard locking elements (not shown), such as
those disclosed in U.S. Pat. No. 4,626,155 issued Dec. 2, 1986 to Hlinsky
et al. The corner fittings 202 at the rear of the container 10 form part
of the rear door frame 174 and are welded in position at the intersections
of the lower crossmember 178 and the rear corner posts 190, and are also
welded to the rear sections 50 of the lower rails 22. The corner fittings
202 at the front of the container 10 are positioned at the base of the
corner posts 98 and are included as part of a front corner connector
assembly 206.
Referring to FIGS. 30-32, each front corner connector assembly 206 (only
one is shown) is provided with means for attaching a corner fitting 202 to
one of the corner posts 98. While various corner fitting attaching means
can be employed, in the illustrated arrangement such means includes an
angled member 210 welded to the top of the corner fitting 202 and inserted
upwardly into the corner post 98. The angled member 210 is shaped to be
somewhat snugly received within the corner post 98 to form a telescopic
lap joint, and an adhesive material (not shown) is preferably applied
between the angled member 210 and the interior surface of the corner post
98. The adhesive material fixes the corner fitting 202 with respect to the
corner post 98. In the illustrated arrangement, optional clamping means,
such as a pair of clamping plates 214 and 218 positioned on opposite sides
of the corner post 98 and secured in place with fasteners 222, is provided
to reinforce the adhesive joint. Each of the corner fittings 202 at the
front of the container 10 are also secured to one of the front sections 46
of one of the lower rails 22, such as by welding.
As shown in FIG. 1, the container 10 also comprises roadside and curbside
side walls 226 and 230 that are preferably identical. Each of the
sidewalls 226 and 230 is constructed of a plurality of modular side panels
234 adjoining one another in series relation to provide a wall structure
of substantially uniform thickness having (see FIG. 7) interior and
exterior surfaces 238 and 242 that preferably occupy parallel planes.
As shown in FIG. 8, each side panel 234 includes a panel member 246 which
in the illustrated arrangement is an integrally formed hollow shell. The
panel member 246 includes a pair of spaced apart and opposed skins or
sheet members 250 and 254 each having an exposed outer surface 258 that
forms part of either the interior surface 238 or the exterior surface 242
of one of the side walls. Each panel member 246 also includes outer end
webs 262 and 266 integrally interconnecting the sheet members 250 and 254
to form opposite lateral sides of the panel member 246.
In the particular embodiment illustrated in the drawings, each side panel
234 is provided with a core of insulating material which is also
preferably expanded foam insulation I. The insulation I, once expanded,
fills the entire interior of the panel member 246 and bonds to the sheet
members 250 and 254. To preserve the integrity of that bond, each panel
member 246 is provided with means for stopping or preventing delamanation
of the sheet members 250 and 254 from the insulation I. While other
delamanation preventing means can be employed, in the illustrated
arrangement delamination is prevented by end webs 262 and 266 which are
load bearing to carry shear loads that might otherwise act to separate the
sheet members 250 and 254 from the insulation I. To avoid moisture
intrusion into the interior of the panel members 246, the webs 262 and 266
also act as a means for sealing the interior of the panel member 246 and
for preventing cross-panel migration of fluids. Thus, if one of the side
walls 226 and 230 is damaged and cannot be immediately repaired, damage
propagation to side panels 234 adjoining the damaged area is prevented.
The replacement of damaged panels 234 is further explained below.
Each of the side walls 226 and 230 is also provided with means for
interconnecting or joining adjacent side panels 234. In the particular
embodiment illustrated in the drawings, the means for interconnecting the
side panels 234 includes means on each side panel for interfitting with
adjoining side panels 234 so that the planar interior and exterior
surfaces 238 and 242 are not interrupted. While various interfitting means
can be employed, in the illustrated arrangement such means is integrated
into each panel member 246 and includes complementary male and female
members 270 and 274, respectively. The male and female members 270 and 274
are integrally formed along the opposite lateral sides of each panel
member 246 and extend along the length thereof.
As shown best in FIGS. 9 and 11, the male member 270 is generally
wedge-shaped and is formed by inwardly offset portions 278 on the sheet
members 250 and 254. Each portion 278 has an outwardly facing tapered
surface 282, and the tapered surfaces 282 of each panel member 212
converge inwardly (in the laterally outward direction) to end web 262. The
female member 274 is formed by a pair of opposed inwardly facing tapered
surfaces 286 on the sheet members 250 and 254. The tapered surfaces 286
converge inwardly (in a laterally inward direction) to the end web 266 to
define a wedge-shaped channel 290. The male member 270 of each side panel
210 is insertable into a corresponding female member 274 of an adjoining
panel to form a joint 292 (see FIG. 9).
The aforementioned interconnecting means also includes means for bonding
adjoining side panels 234 together. While various bonding means can be
employed, the bonding means is preferably entirely confined between the
interior and exterior surfaces 238 and 242 of the side wall so that those
surfaces are not interrupted to provide a clean, smooth container
appearance. The preferred bonding means includes (FIGS. 9 and 11) an
adhesive material A applied at the joints 292, and in particular between
the tapered surfaces 282 and 286 at the joint 292. The adhesive material A
is preferably a methacrylate adhesive sold by ITW Adhesive Systems of
Farmington Hills, Mich. as Model No. A0420. Adhesive Model No. AO20FF may
also be used when a longer cure time is desired.
To insure a proper adhesive bond, the bonded surfaces must be clean prior
to application of the adhesive material A. As is explained more fully
hereinafter, the panel members 246 are preferably formed with fabric
strips 294 (only one is shown in FIG. 11) over each of the tapered
surfaces 282 and 286. Prior to application of the adhesive material A, the
strips 294 are peeled away to provide clean, slightly roughened bonding
surfaces.
The panel members 246 are also provided with means for dispensing adhesive
material A between the directly opposed tapered surfaces 282 and 286 at
each joint 292 without wiping the adhesive material A from between the
tapered surfaces 282 and 286. In the illustrated arrangement, the
dispensing means includes the complementary shapes of the male and female
members 270 and 274. In particular, prior to fit-up the fabric strips 294
are removed from a corresponding pair male and female members 270 and 274
and adhesive material A is preferably laid (FIG. 11) as a bead along the
length of each of the tapered surfaces 286 of the female member 274. When
the male member 270 is inserted into the female member 274, the adhesive
beads are spread or rolled between the male and female members 270 and 274
to form (FIG. 9) substantially uniform and continuous bond lines that
provide a double layer adhesive seal. The thickness of the layers of
adhesive material A is controlled by the degree of insertion of the male
member 270 and by the taper of the male and female members 270 and 274.
Applicant has determined that the tapered surfaces 282 and 286 should
preferably be from 3.degree.-5.degree. for optimum performance.
To further facilitate proper and accurate assembly of the side walls 226
and 230, each joint 292 is provided with means for controlling fit-up
between adjoining side panels 234. The fit-up control means includes means
defining excess adhesive reservoirs at the joint 292. The reservoirs are
formed between the interfitted male and female members 270 and 274 and
include (FIG. 9) spaces 298 and a cavity or air gap 302 between the end
(i.e., the web 262) of the male member 270 and the base (i.e. the web 266)
of the channel 290 of the corresponding female member 274. Excess adhesive
material A in the joint 292 can be relieved into the spaces 298 or the
cavity 302 so as not to interfere with accurate fit-up of adjoining side
panels 234, and the spaces 298 permit convenient visual inspection of the
joint 292. Thus, the possible presence of excess adhesive material A in
the joint 292 will not affect fit-up of adjoining side panels 234.
The cavity 302, and particularly the opposed webs 262 and 266 of
corresponding male and female members 270 and 274 forming the joint 292,
provide means for guiding a suitable cutting tool such as a saw blade to
facilitate separation of adjoining side panels 234. By separating
adjoining side panels along the cavity 302, the integrity of the side
panels 234 as sealed shells for insulation I is maintained. Thus, in the
event one of the side panels 234 becomes damaged it can be quickly and
easily cut from the corresponding side wall without compromising the
structural or thermal performance of the adjoining side panels 234. The
damaged side panel can then be replaced with (FIG. 36) a replacement panel
306 that is provided at its opposite ends with enlarged female members 310
(only one is shown). The female members 310 receive the adjoining panels
and are bonded thereto with adhesive material A.
An alternative joint configuration is illustrated in FIG. 37. That
arrangement includes a panel 314 having portions 318 (only is shown) and a
separate splice plate 322 that receive therebetween one of the side panels
234 to form a splice joint 326. Adhesive material A is also used at the
splice joint 326.
In the particular embodiment illustrated in the drawings, the panel members
246 act as structural members. While each panel member 246 can be made of
a variety of materials, in a preferred embodiment the panel members 246
are made of the same composite material as the aforementioned frame
components and are also formed by pultrusion. Like the pultruded frame
members each panel member 246 includes (FIG. 8) a longitudinal pultrusion
axis 330, and the filamentary material therein is preferably arranged in a
multi-directional array and is dispersed throughout the cross-section of
each panel member 246 to provide structural properties in all directions.
However, the filamentary material is predominantly oriented parallel to
the pultrusion axis 330 to improve load bearing in that direction and to
increase resistance to thermal flux in a direction transverse to that
direction (i.e., across the thickness dimension of the panel member 246).
FIG. 10 shows a portion of one of the webs 262 and 266 to illustrate this
filament arrangement. In particular, R represents the resin material, M
represents fibers arranged in a multi-directional array, and F represents
fibers arranged substantially parallel to the pultrusion axis 330.
As mentioned above, the panel members 246 include peel-away fabric strips
294 on the tapered surfaces 282 and 286, the strips 294 being removed
prior to application of the adhesive material A to provide pre-prepared
bonding surfaces. The fabric strips 294 are integrally formed with the
panel pultrusions as part of the pultrusion operation. The fabric strips
294 are preferably a 5 oz./yd..sup.2 woven DACRON material known as
PEEL-PLY. It is preferred that each pultruded component of the container
10 be pultruded with an integral fabric strip 294 along every adhesive
bonding surface that extends parallel to the pultrusion axis of that
component.
The mounting of both side walls 226 and 230 on the frame 246 is the same
and will be explained with reference to FIG. 7 and the roadside side wall
226. The side wall 226 is positioned with respect the frame 14 such that
it is supported on the tubular portion 30 of one of the lower rails 22
with the outer flange 38 of the lower rail 22 extending upwardly over the
lower end of the exterior surface 242. The upper rail 58 is supported on
top of the side wall 226 with its outer flange 86 extending downwardly
over the exterior surface 242.
Means are provided for securely attaching the side wall 226 to the frame
14. The attachment means preferably includes means that do not intrude
into the interior and exterior surfaces 238 and 242 of the side wall 226
for bonding the side wall 226 to the frame 14 so that those surfaces
remain uninterrupted. In the illustrated embodiment, the bonding means
includes adhesive material A applied between the exterior surface 242 and
each of the outer flanges 38 and 86. The sealed joints thus formed between
the side wall 226 and the lower and upper rails 22 and 58 are fastenerless
to provide a clean, smooth appearance. To seal the upper and lower ends of
the side wall 226, lower and upper angle pultrusions 334 and 338 are
adhesively bonded between the interior surface 238 and the lower and upper
rails 22 and 58, respectively. A pultruded scuff liner 342 is also
adhesively bonded to the interior surface 238 above the lower angle
pultrusion 338.
To connect the side wall 226 to the front frame assembly 94 (FIG. 28), the
male member 270 of the forwardmost side panel 234 is adhesively bonded
between the flanges 110 on the corner post 98 to form a joint like the
joint 292. Thus, the joint between the side wall 226 and the front frame
assembly 94 is also fastenerless.
To connect the side wall 226 to the rear door frame 174, the side wall 226
is provided with non-thermally conductive means for tying or interfacing
with the rear door frame 174. In the illustrated embodiment, the
interfacing means includes (FIG. 34) a pultruded composite side tie member
346 that also preferably has its filamentary material predominantly
oriented in the longitudinal direction to decrease thermal flux
thereacross. The side tie member 346 includes a pair of forwardly
extending flanges 350 that define a male member sized to interfit with and
be adhesively bonded within the female member 274 of the rearmost side
panel 234 to produce a joint similar to joint 292.
The side tie member 346 also includes a first and second rearwardly
extending portions 354 and 358 overlapping spaced apart inner surfaces on
the corner post 190. The portions 354 and 358 are fastened to the post
with lag screws 362 and rivets 366 or other suitable means. Adhesive
material A is also preferably applied between the rearwardly extending
portions 354 and 358 and the roadside rear corner post 190 to seal the
joints therebetween.
As shown in FIGS. 1 and 3, the container 10 also comprises a top wall 370
extending generally perpendicularly to the side walls 226 and 230 and
between the upper rails 58. The top wall 370 has (FIG. 7) interior and
exterior surfaces 374 and 378, respectively, and includes a plurality of
modular roof panels 382. As shown in FIG. 15, the roof panels 382 each
include a panel member 386 that is thicker than the panel members 246 of
the side panels 234 and that includes an integrally formed central web
390. The panel member 386 is otherwise identical to panel members 246 of
the side panels 234, and includes male and female members 394 and 398,
respectively, for interconnecting adjoining roof panels 382. The joints
402 formed by interfitted male and female members 394 and 398 are
preferably identical (except for thickness) to joints 292.
The panel members 386 of the roof panels 382 are also filled with
insulation I, and the panel members 386 are preferably constructed in the
same manner and with the same materials as the panel members 246 of the
side panels 234 to achieve like properties and characteristics. Thus, the
panel members 386 are panel pultrusions each having a pultrusion axis 406
and possessing filamentary material oriented predominantly in a direction
parallel to the pultrusion axis 406.
To form the top wall 370, the roof panels 382 are assembled in the same
manner as described above with respect to the side panels 234. Referring
to FIG. 7, the top wall 370 is supported on the flanges 90 (only one side
is shown) of the upper rails 58. As with the side walls 226 and 230, the
attachment means for fixing the top wall 370 to the frame 246 includes
adhesive material A bonding the top wall 370 to the upper rails 58. The
adhesive material A is applied between the interior surface 374 of the top
wall 370 and the flanges 90 to provide a fastenerless joint that does not
penetrate the interior and exterior surfaces 374 and 378 of the top wall
370. To seal the top of the joint between the upper rail 58 and the top
wall 370, an elongated pultruded panel 410 is adhesively bonded in place
over that joint. The panel 410 is seated partially on the recessed surface
portion 82 and extends over onto the exterior surface 378 of the top wall
370.
As shown in FIG. 29, to connect the top wall 370 to the front frame
assembly 94, the male member 394 of the forwardmost roof panel 382 is
adhesively bonded between the flanges 146 on the upper beam 118. The joint
thus formed is also fastenerless and is similar to the joint 402 between
adjoining roof panels 382.
The top wall 370 is also provided with non-thermally conductive means for
tying with the rear door frame 174. In the illustrated arrangement, such
means includes (FIG. 35) a pultruded composite top tie member 414 similar
to the side tie member 346. The top tie member 414 includes a pair of
forwardly extending flanges 418 that define a male member sized to
interfit with and be adhesively bonded within the female member 398 of the
rearmost roof panel 382. The top tie member 414 also includes first and
second rearwardly extending portions 422 and 426 each overlapping separate
inner surfaces of the upper crossmember 186. The portions 422 and 426 are
fastened to the upper crossmember 186 with screws 430 and rivets 434,
respectively, and adhesive material A is preferably applied between the
joints thus formed to seal those joints.
The container also includes (FIGS. 1 and 5) a front wall 438. As shown in
FIG. 29, the front wall 438 is made of roof panels 382 that interfit with
the male member 154 on the lower beam 122 and the flanges 158 on the
intermediate beam 126.
The container 10 further comprises (FIG. 4) a bottom wall 442 extending
generally perpendicularly to the side walls 226 and 230 and between the
lower rails 22. The bottom wall 442 has interior and exterior surfaces
which in the illustrated arrangement are upper and lower surfaces 446 and
450, respectively. As shown in FIG. 7, an aluminum floor 454 is supported
on the upper surface 446. The floor 454 includes a cargo supporting
surface 458 that is configured to permit air flow beneath the cargo (not
shown).
The bottom wall 442, like the side and top walls 226, 230 and 370, is
modularly constructed of interconnected floor panels 462. As shown in FIG.
13, each of the floor panels 462 includes a panel member 466 that has a
floor section 470. The floor section 470 includes integrally formed
intermediate webs 474 and 478 and an integrally formed central web 482
which is thicker in cross-section than the central web 390 of the roof
panels 382. The additional webs 474 and 478 and the thickened central web
482 are provided to support heavy loads on the upper surface 446 of the
bottom wall 442. Otherwise, the floor sections 470 are preferably
identical to the panel members 386 of the top panels 382, and each is
provided with male and female members 478 and 486 forming joints 490
between adjoining panels. The joints 490 are preferably identical to the
joints 402 between adjoining roof panels 382.
Each floor panel member 466 also includes means for stiffening its floor
section 470 to resist bending moments resulting from downwardly directed
forces on the upper surface 446 of the bottom wall 442. While various
stiffening means can be employed, in the illustrated arrangement such
means includes (FIG. 13) a reinforcing section 494 formed as an integral
part of the panel member 466. The reinforcing section 494 is generally
trapezoidal in shape and includes a pair of legs 498 and 502 that extend
downwardly from the floor section 470. The leg members 498 and 502 form
extensions of the central web 482 and one of the outer end webs so that
the reinforcing section 494 is offset toward one of the joints 490 to also
reinforce that joint against bending moments. The reinforcing section 494
also includes a base 506 that is parallel to the sheet members of the
floor section 470 and that extends between the lower ends of the leg
members 498 and 502.
The floor sections 470 of the floor panels 462 are filled with insulation
I, and the floor panels 462 are preferably constructed in the same manner
and with the same materials as the panel members 246 and 386. Thus, the
panel members 466 are panel pultrusions each having a pultrusion axis 510
and possessing filamentary material oriented predominantly in a direction
parallel to the pultrusion axis 510.
To form the bottom wall 370, the roof panels 382 are assembled in the same
manner as described above with respect to the side panels 234. Prior to
assembly of the bottom wall 370, the floor panels 462 are preferably
notched to accommodate the frame 14. As shown in FIG. 14, the ends of each
floor section 470 are preferably cut to form 45.degree. notches 514, and
the ends of the reinforcing section 494 are cut off to provide outer
stepped portions 518. The middle portions of the reinforcing section 494
are also cut on floor panels 462 at the front of the container 10 to
provide inner stepped portions 522.
Attachment of one side of the bottom wall 442 to one of the lower rails 22
is shown in FIG. 7. In particular, the lateral end of the bottom wall 442
shown in FIG. 7 fits over the lower rail 22 such that the floor and
reinforcing sections 470 and 494 of each floor panel 462 are supported on
the upper surface of the tubular portion 30 and the flange 42,
respectively. The notches 514 and the outer stepped portions 518
accommodate the angle pultrusion 338 and the tubular portion 30 of the
lower rail 22, respectively. As shown best in FIGS. 4 and 5, the inner
stepped portions 522 provide space for the channel 170 and the steel
members 162 preferably fit over the inner stepped portions 522.
As with the side and top walls 226, 230 and 370, the attaching means for
securing the bottom wall in place is fastenerless and includes adhesive
material A. The adhesive material A is applied between the flange 42 and
the lower surface of the reinforcing sections 494, and can also be
provided between the floor section 470 and the upper surface of the
tubular portion 30, if desired.
As shown in FIG. 29, to connect the bottom wall 370 to the front frame
assembly 94, the male member 478 of the forwardmost floor panel 462 is
adhesively bonded between the flanges 150 of the lower beam 122. The joint
thus formed is also fastenerless and is similar to joint 490.
To connect the bottom wall 370 to the rear door frame 174 (FIG. 33),
adhesive material A is applied between the rearmost floor panel 462 and
the lower crossmember 178. A resilient ramp 530 is also provided to form a
smooth transition between the lower door sill 182 and the aluminum floor
454. The ramp 530 is supported on a plate 534 that is riveted to the lower
crossmember 178.
The container 10 also comprises means for supporting one or more additional
containers C (a portion of one of which is schematically shown in FIG. 1)
thereon so that the container 10 can be positioned in a vertically stacked
arrangement with other containers. While various supporting means can be
employed, in the illustrated arrangement the supporting means includes
(FIGS. 1-3) two stacking frame assemblies 538 which each form part of the
frame 14. The stacking frame assemblies 538 are positioned at spaced
intermediate locations, and are preferably spaced inwardly from the ends
of the container 10 so that the container 10 can be stacked
interchangeably with other domestic containers or with ISO containers, as
will be understood by one skilled in the art.
Each of the stacking assemblies 538 includes a pair of stacking posts 542
positioned directly opposite one another in one of the side walls 226 and
230. The stacking posts 542 are preferably identical and one is
illustrated in FIG. 12. The illustrated stacking post 542 is contained
within the confines of the side wall 226 and includes outwardly facing
surfaces 546 and 550 and an inwardly facing surface 554 that form parts of
the interior and exterior surfaces 238 and 242, respectively. Thus, in the
illustrated arrangement the overall thickness of the stacking post 542 is
no greater than the thickness of the side wall 226. The stacking post 542
also includes a recessed surface 558.
To integrate the stacking posts 542 as modular parts of the side walls 226
and 230, each stacking post 542 is provided with means for interfitting
with the side panels 234. While various interfitting means can be
employed, in the embodiment illustrated in FIG. 26 the interfitting means
includes sets of spaced apart sets of flanges 562 and 566. The flanges 562
and 566 form male and female members on the opposite ends of the stacking
post 542 that are configured to interfit with the female and male members
274 and 270 of adjoining side panels 234 to form joints similar to joints
292.
The stacking posts 542 substantially support the weight of any container(s)
C stacked on top of the container 10. To impart the needed strength to the
stacking posts 542, each is preferably made of the aforementioned
composite material and is formed as a post pultrusion having a vertically
extending pultrusion axis 570. As with the aforementioned pultruded parts,
the post pultrusion has a multi-directional array of filamentary material
with a predominance of the fibers oriented parallel to the pultrusion axis
570 to achieve the aforementioned desired structural and thermal
advantages. In the arrangement illustrated in FIG. 12 the pultruded
stacking post 542 are generally tubular and are filled with insulation I.
Each stacking frame assembly 538 also includes (FIGS. 1 and 3) a horizontal
crossmember or beam 574 within the confines of the top wall 370. As shown
in FIG. 16, the horizontal beam 574 includes inwardly facing surfaces 578
and 582 and an outwardly facing surface 586 that form parts of the
interior and exterior surfaces 374 and 378, respectively. The horizontal
beam 574 also includes a recessed surface 590, and is preferably pultruded
of composite material to achieve thermal and structural advantages similar
to the other pultruded frame components.
To interface with adjoining roof panels 382 to form a modular part of the
top wall 370, the horizontal beam 574 includes (FIG. 16) sets of flanges
594 and 598 that act as male and female members to interfit with the
adjoining roof panels 382 to form joints like joints 402.
Each of the stacking frame assemblies 538 is also provided with means for
connecting the container 10 to a container stacked thereabove. While
various connecting means can be employed, in the illustrated arrangement
the connecting means includes (FIGS. 1-3) two upper intermediate connector
assemblies 610 each positioned at an intersection of one of the corner
posts 542, the beam 574, and one of the upper rails 58. Each upper
connector assembly 610 includes a hollow upper locking element receiving
fitting 614 which in the illustrated arrangement is a standard fitting
used for intermediate locations.
Since the frame components are made of composite material conventional
means (i.e., weldment) cannot be used to secure the fitting 614 in place
on the container 10. Accordingly, each upper connector assembly 610 is
provided with means for mounting a fitting 614 on the container 10. In the
illustrated embodiment the mounting means includes lap joint means for
attaching the fitting 614 to one of the stacking posts 542. Referring to
FIGS. 17-23, the lap joint means for attaching the fitting 614 to one of
the stacking posts 542 includes a pair of spaced apart metal splice plates
618 and reinforcing plates 622. To attach the plates 618 and 622 to the
fitting, the lower edges of the splice plates 618 are preferably ground
off to provide a pocket which is filled with weldment 626 (FIG. 23).
As shown in FIGS. 18 and 19, the splice plates 618 overlap one of the
stacking posts 542 so that the post is sandwiched therebetween to form a
double lap joint. That lap joint is provided with a layer of adhesive
material A between each of the splice plates 618 and the stacking post 542
to provide a tight, sealed union between those parts. To prevent the
splice plates 618 from increasing the overall width of the container 10,
the outer one of the splice plates 618 is seated on the recessed surface
558.
The mounting means also includes second, third and fourth lap joint means
for attaching the fitting 614 to the top beam 574 and to one of the upper
rails 58. In the illustrated arrangement the second, third and fourth lap
joint means include tubular members 630, 634 and 638, respectively. The
tubular members 630, 634 and 638 are received in the top beam 574 and in
the upper rail 58 to form telescopic lap joints. Adhesive material A is
applied at each of those joints to provide a sealed secure union.
To reinforce the tubular members 630, 634 and 638, shortened reinforcing
tubes 642 are provided. To attach the tubular members to the fitting 614,
the lower edge of the associated reinforcing tube 642 is first ground off
as indicated by the line 646 in FIG. 24. The pocket thus formed is then
filled with weldment 650 (FIG. 22) to attach both the tubular member and
the reinforcing tube 634 to the fitting 614.
The adhesive material A at each of the aforementioned lap joints absorbs
shear loads and provides a zero tolerance or "no-slop" joint as well as
sufficient stiffness to prevent any loads from "peeling" the lap joints
apart. To provide further support, each of the lap joint means also
includes optional clamping means for reinforcing the lap joints. In the
illustrated arrangement, each of the clamping means includes fasteners
654, such as nuts and bolts, extending through the joints. The clamping
means at the telescopic joints also include (FIGS. 17-19) sets of metal
clamping plates 658, 662 and 666. To support the stacking post 542 against
the compressive loads resulting when the fasteners 654 are tightened,
reinforcing means is provided at the double lap joint formed by the splice
plates 618. As shown in FIG. 19, the reinforcing means includes a block
670 made of wood or other suitable material and inserted into the upper
end of the stacking post 542 directly between the splice plates 618.
Each of the stacking frame assemblies 538 is also provided with means for
connecting the container 10 to another container (not shown) on which the
container 10 is stacked. In the embodiment illustrated in the drawings,
the means for connecting the container 10 to a lower container includes
(FIG. 4) a pair of lower intermediate connector assemblies 674 at the
intersections of the stacking posts 542 with the lower rails 22.
Referring to FIGS. 25-27, each lower connector assembly 674 includes a
standard lower fitting 678 and first lap joint means for attaching the
fitting 678 to the lower end of one of the stacking posts 542. In the
illustrated arrangement, such means includes splice plates 682 and
reinforcing plates 686 that extend upwardly over the stacking post 542
from the top surface of the fitting 678. The double lap joint thus formed
is preferably substantially identical to the double lap joint formed by
the splice plates 618 of the upper intermediate connector assembly 610.
Additional clamping fasteners 654 are also provided to reinforce the
adhesive bond at the double lap joint formed by splice plates 682.
The lower connector assembly 674 is also provided with a tubular member 690
that is preferably welded to the lower fitting 678 using the same
technique as described above with respect to attaching tubular members
630, 634 and 638 to the upper fitting 614. The tubular member 690 is
received within one of the lower rails 22 and is adhesively bonded thereto
to form another telescopic joint. As shown in FIGS. 25 and 26, that joint
is provided with a pair of clamping plates 694 extending over the upper
and lower surfaces of one of the lower rails and clamped thereto with
fasteners 698 to reinforce the joint.
To manufacture the container 10, elongated specimens having desired
cross-sectional shapes are pultruded and cut to appropriate lengths to
form the various pultrusions used to assemble the container 10.
Preferably, fabric strips 294 are integrally incorporated into each
pultrusion on all surfaces that extend along the axis of pultrusion and
that form bonding surfaces. To finish the pultruded parts, those that are
to be insulated are filled with insulation I by spraying liquified foam
into the pultrusions and allowing the foam to expand and cure.
With the necessary parts on hand, the side, top and bottom walls 226, 230,
370 and 442 are assembled by removing fabric strips 294 from corresponding
male and female members and interfitting and bonding those members
together in the manner set forth above. For purpose of assembly, the
stacking posts 542 are treated as side panels 234 and the beam 574 is
treated as a roof panel 382.
The frame 14 is preferably assembled in sections including the front frame
assembly 94 and the rear door frame 174, and the lower and upper rails 22
and 58 are bonded to the side panels 234 to form side wall assemblies.
Upon completion of the top and bottom walls 370 and 442, the side wall
assemblies are positioned on opposite sides of the bottom wall 320 and are
adhesively bonded thereto as described above. The aluminum floor section
454 can be installed before or after mounting the side wall assemblies on
the bottom wall 442. Thereafter, the top wall 370 is placed on the upper
rails 58 and bonded thereto, and the front frame assembly 94 and the rear
door frame 174 are interfitted and bonded to the side, top and bottom
walls 226, 230, 370 and 374 as previously described.
Illustrated in FIGS. 38-41 are portions of side walls including alternative
stacking post configurations. In particular, composite stacking posts can
be customized for optimum performance in a variety of applications, and
can be pultruded or otherwise produced as hybrids, if desired. For
example, FIG. 38 illustrates a multi-layered stacking post 702 having a
core or inner layer 706 which is configured similarly to stacking posts
542, and outer layers 710 and 714 sandwiching the inner layer 706. In the
illustrated arrangement, the stacking post 702 is formed throughout its
cross-section with a single resin binder material, but has different
filamentary materials occupying the separate layers. All of the
filamentary material is preferably predominantly oriented in the
lengthwise direction of the stacking post 702 (i.e., parallel to its axis
of pultrusion).
In one embodiment, the outer layers 710 and 714 include carbon fibers 718
that have a modulus which is greater than that of the glass fibers in the
inner layer 706 to increase the column stability and stiffness of the
stacking post 702. This provides the stacking post 702 with increased load
bearing ability. A suitable application for stacking post 702 is in
insulated or refrigerated ISO containers which may be vertically stacked
several high.
Illustrated in FIG. 39 is a stacking post 722 which is similar to stacking
post 702, but which includes a discontinuous outer layer 726. This
arrangement is expected to provide column stiffness and thermal
performance intermediate that of stacking posts 542 and 702.
Illustrated in FIG. 40 is a stacking post 730 which is pultruded, or
otherwise formed, as a solid multi-layered plank. The stacking post 730 is
contemplated for use in intermodal containers in which minimum wall
thickness and maximum interior dimensions are desired, such as in
non-insulated ISO containers. In the illustrated embodiment, stacking post
730 includes an inner layer 734 of composite material including glass
fibers and outer layers 738 of composite material including carbon fibers.
Illustrated in FIG. 41 is a stacking post 742 including a single layer of
composite material having glass fibers. Stacking post 742 might be used,
for example, in non-insulated domestic containers.
Illustrated in FIGS. 42-46 is a container 746 in accordance with a second
embodiment of the invention. The container 746 is an insulated ISO
container which is not provided with an opening to accomodate a
refrigeration unit and which is not configured to receive a trailer
chassis. Otherwise, the container 746 is similar in many respects to the
container 10, and the same reference numerals are used for common
components.
The container 746 includes a front stacking frame assembly 750 at the front
end of the container 746. The stacking frame assembly 750 includes a pair
of stacking posts 754 that are positioned at the front corners of the
container 746. As shown in FIG. 46, the stacking posts 754 are similar to
the stacking posts 542 used in container 10 except that the stacking posts
754 have had the set of flanges 598 removed therefrom. Instead, the
stacking posts 754 each include an angle pultrusion 758 adhesively bonded
to the inner surface thereof, and a plate pultrusion 762. To accomodate
the angle pultrusion 758, each of the roof panels 382 in the front wall is
provided with notches 766.
Various features and advantages of the invention are set forth in the
following claims.
Top